US20240194993A1 - Battery Housing - Google Patents

Battery Housing Download PDF

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Publication number
US20240194993A1
US20240194993A1 US18/286,676 US202218286676A US2024194993A1 US 20240194993 A1 US20240194993 A1 US 20240194993A1 US 202218286676 A US202218286676 A US 202218286676A US 2024194993 A1 US2024194993 A1 US 2024194993A1
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United States
Prior art keywords
fiber
battery housing
highly heat
battery
resistant
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US18/286,676
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English (en)
Inventor
Akihiro Yano
Hideyuki SHIRAKU
Kazunori Kawahara
Nobuaki Takata
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Mitsubishi Chemical Corp
Maftec Co Ltd
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Maftec Co Ltd
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Publication date
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Assigned to MAFTEC CO., LTD. reassignment MAFTEC CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MITSUBISHI CHEMICAL CORPORATION
Assigned to MITSUBISHI CHEMICAL CORPORATION reassignment MITSUBISHI CHEMICAL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: YANO, AKIHIRO, TAKATA, NOBUAKI, KAWAHARA, KAZUNORI, SHIRAKU, Hideyuki
Publication of US20240194993A1 publication Critical patent/US20240194993A1/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/043—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/229—Composite material consisting of a mixture of organic and inorganic materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/047—Reinforcing macromolecular compounds with loose or coherent fibrous material with mixed fibrous material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/247—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using fibres of at least two types
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/121—Organic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/131—Primary casings; Jackets or wrappings characterised by physical properties, e.g. gas permeability, size or heat resistance
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/202—Casings or frames around the primary casing of a single cell or a single battery
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/222—Inorganic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/227—Organic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/231—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks having a layered structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/293—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by the material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10—Homopolymers or copolymers of propene
    • C08J2323/12—Polypropene
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention relates to a battery housing.
  • Weight reduction has become an issue in order to improve energy efficiency for transportation machinery using motors in general. Focusing on the battery housing, conventionally metal materials have been used, and there has been a problem of heavy weight.
  • Aluminum is an example of a lightweight metal; however, because it has a low melting point, it is easily penetrated by a flame generated when thermal runaway of the battery occurs. Oxygen is supplied through the penetrated through hole, causing explosive combustion, making aluminum unsuitable for use.
  • Another considerable example of the lightweight material is resin; however, it is difficult to use because it has insufficient flame shielding performance and rigidity for use as a battery housing.
  • PTL 1 has proposed a battery case for vehicles, which is formed by molding a carbon fiber-reinforced polypropylene resin composition obtained by blending 8 to 70 parts by weight of a carbon fiber and 0.6 to 37.5 parts by weight of a flame retardant with respect to 100 parts by weight of a polypropylene resin, where the carbon fiber in the molded article has a weight average fiber length of 0.5 mm or more and less than 3 mm.
  • the energy density of a battery module tends to increase in order to extend driving distance of electric vehicles. Therefore, a battery housing made of a reinforced resin is also required to have higher flame shielding performance.
  • an object of the present invention is to provide a battery housing made of a fiber-reinforced resin capable of delaying the spread of fire to an automobile interior member when thermal runaway of a battery occurs and flame is generated, and having excellent flame shielding performance.
  • the present inventors have made extensive studies and found that the above problems can be solved by a battery housing using a fiber-reinforced resin containing at least an inorganic fiber having a melting temperature or a burn-out temperature of higher than 1000° C. in an air atmosphere, and based on these findings, have completed the present invention.
  • the present invention provides the following [1] to [12].
  • a battery housing capable of delaying the spread of fire to an automobile interior member when thermal runaway of a battery occurs and flame is generated, and having excellent flame shielding performance.
  • FIG. 1 is a conceptual view illustrating a battery housing.
  • FIG. 2 is a model view indicating a stampable sheet of Example 1.
  • FIG. 1 is a conceptual view showing a structure such as a battery including a battery housing.
  • a structure 10 such as a battery includes, for example, a battery module 11 that is an assembly of battery cells (battery units), a battery pack 12 that is an assembly of battery modules, and a battery housing 13 for housing battery members such as a battery pack.
  • the battery housing of the present invention is made of a fiber-reinforced resin, and contains, as the fiber, a highly heat-resistant fiber A having a melting temperature or a burn-out temperature of higher than 1000° C. in an air atmosphere, and an inorganic fiber B (hereinafter may simply be referred to as “inorganic fiber B”) having a melting temperature or a burn-out temperature lower than that of the highly heat-resistant fiber A.
  • the fiber in the fiber-reinforced resin according to the present invention may be an organic fiber or an inorganic fiber.
  • an inorganic fiber is preferable from the viewpoint of heat resistance, and examples thereof include glass fiber, rock wool, basalt fiber, alumina fiber, silica alumina fiber, potassium titanate fiber, calcium silicate (wollastonite) fiber, and alkaline earth silicate fiber (biosoluble). These inorganic fibers may be used alone or in combination of two or more kinds thereof.
  • the fiber includes a highly heat-resistant fiber A with a melting temperature or a burn-out temperature of higher than 1000° C. in an air atmosphere.
  • the highly heat-resistant fiber include alumina fiber, potassium titanate fiber, silica alumina fiber, alkaline earth silicate fiber (biosoluble), and basalt fiber. Of these, alumina fiber is particularly preferred.
  • the highly heat-resistant fiber can be used alone or in combination of two or more kinds thereof.
  • the fiber includes, in addition to the above-described highly heat-resistant fiber A, an inorganic fiber B having a melting temperature or a burn-out temperature lower than that of the highly heat-resistant fiber A.
  • an inorganic fiber B having a melting temperature or a burn-out temperature lower than that of the highly heat-resistant fiber A.
  • the content of the highly heat-resistant fiber A is preferably 1 part by mass or more, more preferably 3 parts by mass or more, and still more preferably 5 parts by mass or more, with respect to 100 parts by mass of the fiber-reinforced resin.
  • the upper limit is preferably 20 parts by mass or less, more preferably 15 parts by mass or less, and even more preferably 10 parts by mass or less.
  • the fiber of the present invention must contain the highly heat-resistant fiber A as described above, and must also contain the inorganic fiber B having a melting temperature or a burn-out temperature lower than that of the highly heat-resistant fiber A.
  • glass fibers are suitable as the inorganic fiber B, and the fiber in the present invention particularly preferably includes alumina fiber and glass fiber.
  • the mass ratio to the highly heat-resistant fiber A is required to be in the range of more than 1 to 8, and preferably in the range of 2 to 6.
  • the highly heat-resistant fiber A such as alumina fiber
  • the inorganic fiber B such as glass fiber
  • the fiber-reinforced resin or a mat of the highly heat-resistant fiber A such as alumina fiber and a mat of the inorganic fiber B such as glass fiber, which will be described in detail later, may be laminated and impregnated with a resin to obtain a sheet-shaped product.
  • the fiber used in the present invention may be used in combination with a sizing agent or a surface treatment agent.
  • a sizing agent or surface treatment agent include a compound having a functional group, such as an epoxy compound, a silane compound, and a titanate compound.
  • the fiber of the present invention includes the highly heat-resistant fiber A and the inorganic fiber B, and at least one kind of the fibers preferably has an average fiber diameter of 3 to 25 ⁇ m and preferably has an average fiber length of 5 mm or more.
  • the average fiber diameter and the average fiber length of the highly heat-resistant fiber A are preferably within the above ranges.
  • the average fiber length of the inorganic fiber B is preferably greater than the average fiber length of the highly heat-resistant fiber A.
  • the fiber diameter can be measured using an optical microscope or the like, and the average fiber diameter can be obtained, for example, by randomly measuring the fiber diameters of 10 fibers and calculating the average value.
  • the fiber length can be measured using a ruler, vernier caliper, or the like from an image magnified with a microscope or the like, when necessary.
  • the average fiber length can be obtained, for example, by randomly measuring the fiber lengths of 10 fibers and calculating the average value.
  • the fiber content in the fiber-reinforced resin of the present invention is preferably 3 to 60% by mass.
  • the fiber content is 3% by mass or more, the strength, rigidity, and impact resistance of the battery housing can be ensured.
  • the fiber content is 60% by mass or less, the battery housing can be easily produced and processed. Further, when the fiber content is 60% by mass or less, the specific gravity decreases, and there is an advantage that the effect of weight reduction as a metal substitute is large.
  • the fiber content in the fiber-reinforced resin is more preferably 10 to 50% by mass, and further preferably 30 to 45% by mass.
  • fiber as used herein includes the highly heat-resistant fiber A and the inorganic fiber B described above.
  • the resin constituting the fiber-reinforced resin of the present invention is not particularly limited, it can be a thermoplastic resin.
  • the thermoplastic resin is not particularly limited, and examples thereof include polyolefin resins such as polyethylene and polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, and polyurethane.
  • a polyolefin resin is preferred, and a polypropylene-based resin is particularly preferred, in terms of physical properties, versatility, cost, etc. of the resin.
  • polypropylene-based resin examples include a propylene homopolymer and a propylene- ⁇ -olefin copolymer.
  • the propylene- ⁇ -olefin copolymer may be either a random copolymer or a block copolymer.
  • the content of the thermoplastic resin in the battery housing of the present invention is preferably 20 to 80% by mass.
  • the content of the thermoplastic resin is 20% by mass or more, the molding workability is sufficient, and the molding of the battery housing becomes easy.
  • the content of the thermoplastic resin is 80% by mass or less, the content of the inorganic fiber becomes sufficient, and sufficient flame shielding performance can be obtained.
  • the content of the thermoplastic resin in the battery housing is preferably 35 to 70% by mass, and more preferably 40 to 60% by mass.
  • any additive component can be blended for a purpose of imparting other effects, such as further improving the effects of the present invention, within a range that does not significantly impair the effects of the present invention.
  • a colorant such as a pigment, a light stabilizer such as a hindered amine-based light stabilizer, a UV absorber such as a benzotriazole-based UV absorber, a nucleating agent such as a sorbitol-based nucleating agent, an antioxidant such as a phenol-based and a phosphorus-based antioxidant, an antistatic agent such as a nonionic surfactant, a neutralizing agent such as an inorganic compound, an antibacterial and antifungal agent such as a thiazole-based antibacterial and antifungal agent, a flame retardant such as a halogen compound, a plasticizer, a dispersant such as an organic metal salt-based dispersant, a lubricant such as a fatty acid amide-based lubricant, a metal deactivator such as a nitrogen compound, a polyolefin resin other than the aforementioned polypropylene-based resin, a thermoplastic resin such as a polyamide resin
  • These optional additive components may be used in combination of two or more kinds thereof.
  • the colorant for example, an inorganic or organic pigment and the like are effective in imparting and improving colored appearance, attractiveness, texture, commercial value, weather resistance, durability, etc. of the polypropylene-based resin composition and a molded article thereof.
  • the inorganic pigment include carbon black, such as furnace carbon and ketjen carbon; titanium oxide; iron oxide (red iron oxide, etc.); chromic acid (chrome, etc.); molybdic acid; selenide sulfide; and ferrocyanide.
  • the organic pigment examples include a sparingly soluble azo lake, a soluble azo lake, an insoluble azo chelate; a condensable azo chelate; an azo pigment such as other azo chelates; a phthalocyanine pigment, such as phthalocyanine blue and phthalocyanine green; a threne-based pigment, such as anthraquinone, perinone, perylene, and thioindigo; a dye lake; a quinacridone-based pigment; a dioxazine-based pigment; and an isoindolinone-based pigment.
  • an aluminum flake or a pearl pigment can be contained to give a metallic tone or a pearly tone.
  • a dye can also be contained.
  • a hindered amine compound, a benzotriazole-based, benzophenone-based, or salicylate-based light stabilizer or UV absorber is effective in imparting and improving the weather resistance and durability of the polypropylene-based resin composition and a molded article thereof, and is effective in further improving weather-resistance discoloration properties.
  • hindered amine compound examples include a condensation product of dimethyl succinate and 1-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethylpiperidine; poly[[6-(1,1,3,3-tetramethylbutyl)imino-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidyl)imino]hexamethylene[(2,2,6,6-tetramethyl-4-piperidyl)imino]]; tetrakis(2,2,6,6-tetramethyl-4-piperidyl)1,2,3,4-butanetetracarboxylate; tetrakis(1,2,2,6,6-pentamethyl-4-piperidyl)1,2,3,4-butane tetracarboxylate; bis(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate; and bis-2,2,6,6-tetramethyl-4-piperidine
  • Examples of a benzotriazole-based one include 2-(2′-hydroxy-3′,5′-di-t-butylphenyl)-5-chlorobenzotriazole; and 2-(2′-hydroxy-3′-t-butyl-5′-methylphenyl)-5-chlorobenzotriazole.
  • Examples of a benzophenone-based one include 2-hydroxy-4-methoxy benzophenone; and 2-hydroxy-4-n-octoxy benzophenone.
  • Examples of a salicylate-based one include 4-t-butylphenyl salicylate; and 2,4-di-t-butylphenyl 3′,5′-di-t-butyl-4-hydroxy benzoate.
  • a method of using the light stabilizer and the UV absorber in combination is preferable because it has a large effect of improving weather resistance, durability, weather-resistance discoloration properties, and the like.
  • an antioxidant for example, a phenol-based, phosphorus-based or sulfur-based antioxidant is effective in imparting and improving heat resistance, processing stability, heat aging resistance, and the like of the polypropylene-based resin composition and a molded article thereof.
  • an antistatic agent for example, a nonionic or cationic antistatic agent is effective in imparting and improving the antistatic property of the polypropylene-based resin composition and a molded article thereof.
  • the olefin-based elastomer examples include an ethylene/ ⁇ -olefin copolymer elastomer, such as an ethylene/propylene copolymer elastomer (EPR), an ethylene/butene copolymer elastomer (EBR), an ethylene/hexene copolymer elastomer (EHR), and an ethylene/octene copolymer elastomer (EOR); an ethylene/ ⁇ -olefin/diene terpolymer elastomer, such as an ethylene/propylene/ethylidene norbornene copolymer, an ethylene/propylene/butadiene copolymer, and an ethylene/propylene/isoprene copolymer, and a styrene/butadiene/styrene triblock copolymer elastomer (SBS).
  • EPR ethylene/propylene copolymer
  • styrene-based elastomer examples include a styrene-based elastomer, such as a styrene/isoprene/styrene triblock copolymer elastomer (SIS), a styrene-ethylene/butylene copolymer elastomer (SEB), a styrene-ethylene/propylene copolymer elastomer (SEP), a styrene-ethylene/butylene-styrene copolymer elastomer (SEBS), a styrene-ethylene/butylene-ethylene copolymer elastomer (SEBC), a hydrogenated styrene/butadiene elastomer (HSBR), a styrene-ethylene/propylene-styrene copolymer elastomer (SEPS), a styrene-ethylene/ethylene/ethylene
  • an ethylene/octene copolymer elastomer (EOR) and/or an ethylene/butene copolymer elastomer (EBR) is used from the viewpoint that the polypropylene-based resin composition of the present invention and a molded article thereof tend to be easily imparted with appropriate flexibility and have excellent impact resistance.
  • the thickness of the battery housing of the present invention is not particularly limited, it is preferably 0.5 mm or more, more preferably 1.0 mm or more, and even more preferably 2.0 mm or more.
  • the thickness of the battery housing is preferably 10 mm or less, more preferably 8 mm or less, and particularly preferably 6 mm or less. It is preferable that the thickness is equal to or less than the above upper limit, because it is easy to adapt to the size of the space in which it is arranged, as well as from the viewpoint of weight reduction and moldability.
  • press molding is preferable from the viewpoint of productivity.
  • the stampable sheet containing a highly heat-resistant fiber is sandwiched between other stampable sheets from both sides such that the highly heat-resistant fiber can easily flow over the entire sheet.
  • the stampable sheet is preferably produced by impregnating a mat made of fibers with a thermoplastic resin composition.
  • impregnation methods include a method of applying a thermoplastic resin composition to a fiber mat such as an inorganic fiber mat, and a method of preparing a sheet of a thermoplastic resin composition, laminating the sheet on a fiber mat, and heating and melting to impregnate the sheet.
  • thermoplastic resin sheet on a fiber mat from the viewpoint of surface smoothness of the stampable sheet, a method of laminating a thermoplastic resin sheet on a fiber mat and heating and melting is preferred.
  • it can be obtained by laminating a fiber mat between two thermoplastic resin sheets, then heating and pressurizing the laminate, and then cooling and solidifying the laminate.
  • the thermoplastic resin composition is a resin composition containing a thermoplastic resin and optional additives, etc., excluding the fiber.
  • a conventionally known method can be used, and the composition can be produced by blending, mixing, and melt-kneading the above components.
  • Melt kneading is performed by melt-kneading and granulating using equipment such as a single screw extruder, a twin screw extruder, a Banbury mixer, a roll mixer, a Brabender plastograph, and a kneader.
  • the form of the fibers used in the stampable sheet production method is not particularly limited, and various forms can be used. However, those in the form of a mat or sheet are preferred.
  • highly heat-resistant fiber mat a mat formed of highly heat-resistant fibers typified by alumina fibers
  • glass fiber mat a mat formed of glass fibers
  • the basis weight (mass per unit area) of the fiber mat is not particularly limited and is appropriately determined according to the application. However, it is preferably 300 g/m 2 or more, more preferably greater than 500 g/m 2 , further preferably greater than 700 g/m 2 , still more preferably greater than 900 g/m 2 , and particularly preferably greater than 1000 g/m 2 .
  • the basis weight of the fiber mat is not particularly limited; however, it is preferably 5000 g/m 2 or less, more preferably 4500 g/m 2 or less, still more preferably 4000 g/m 2 or less, and particularly preferably 3500 g/m 2 or less.
  • the thickness of the fiber mat according to the present invention is not particularly limited, it is preferably 4 mm or more, more preferably 5 mm or more, and even more preferably 6 mm or more. Also, the thickness of the fiber mat is preferably 40 mm or less, more preferably 35 mm or less, and particularly preferably 30 mm or less.
  • the basis weight per unit area or the thickness of the fiber mat can be set within the above range by adjusting the amount of fiber per unit area when fiber aggregates constituting the fiber mat are laminated using a folding device.
  • the fiber mat of the present invention may have a structure in which a plurality of fiber mats are bonded together or a single structure.
  • a single structure is preferred from the viewpoint of handling properties and peel strength at a bonding interface.
  • Examples of the form of the glass fiber mat used in the present invention include felt and blanket processed with short glass fiber cotton, a chopped strand mat obtained by processing continuous glass fiber, a swirl (spiral) mat of continuous glass fiber, and a unidirectional aligned mat.
  • a glass fiber mat obtained by needle-punching a swirl (spiral) mat of continuous glass fiber is particularly preferable because the strength and impact resistance of the stampable sheet are excellent.
  • the highly heat-resistant fiber mat according to the present invention is a mat that is composed of highly heat-resistant fibers and has undergone a needling treatment. Therefore, the mat has needle marks formed by the needling treatment. That is, when a needling treatment is performed where a needle with a barb is thrusted into and pulled out from a highly heat-resistant fiber assembly, at least a part of the fibers are extended substantially in a thickness direction by the needle at a location where the needle is thrusted and pulled out. As a result, needle marks are formed on the surface of the highly heat-resistant fiber mat.
  • bundles of highly heat-resistant fibers formed substantially in the thickness direction existing inside the highly heat-resistant fiber mat that has undergone the needling treatment are called longitudinal filaments.
  • the longitudinal filaments that exist inside the highly heat-resistant fiber mat are effective longitudinal filaments.
  • a longitudinal filament having a diameter of 100 ⁇ m or more and a protruding length of 2 mm or more is an effective longitudinal filament.
  • the needling treatment is used to adjust the bulk density, peel strength, surface pressure (surface pressure after high temperature cycle), and repulsive force durability (surface pressure retention rate after high temperature cycle) of the alumina fiber mat by forming longitudinal filaments.
  • an effective longitudinal filament means, of the longitudinal filaments that exist substantially in the thickness direction inside the highly heat-resistant fiber mat, one that has a diameter and length that can function as a longitudinal filament.
  • the volume of the effective longitudinal filaments means the volume of the area protruding from the peeling surface.
  • an alumina fiber mat it is preferable to use an alumina fiber mat.
  • thermoplastic resin sheet on a fiber mat In a method of laminating a thermoplastic resin sheet on a fiber mat and heating and melting, appropriate conditions may be selected according to the types of thermoplastic resins. Preferred conditions where polypropylene is used are described below.
  • the heating temperature is preferably 170 to 300° C.
  • the heating temperature is 170° C. or higher, the polypropylene-based resin has sufficient fluidity, the fiber mat can be sufficiently impregnated with the polypropylene composition, and a suitable stampable sheet can be obtained.
  • the heating temperature is 300° C. or less, the polypropylene composition will not deteriorate.
  • the applied pressure is preferably 0.1 to 1 MPa.
  • the fiber mat can be sufficiently impregnated with the polypropylene composition, and a suitable stampable sheet can be obtained.
  • the pressure is 1 MPa or less, the polypropylene composition will flow and burrs will not occur.
  • the cooling temperature is not particularly limited as long as it is equal to or lower than the freezing point of the thermoplastic resin in the polypropylene composition. However, when the cooling temperature is 80° C. or lower, the obtained stampable sheet is not deformed when taken out. From the above point of view; the cooling temperature is preferably room temperature to 80° C.
  • Methods for obtaining a stampable sheet by heating, pressurizing, and cooling the laminate include a method of press-molding the laminate in a mold equipped with a heating device, and a lamination processing of passing the laminate between two pairs of rollers equipped with a heating device to heat and pressurize the laminate.
  • lamination processing is preferable because it allows continuous production, resulting in good productivity.
  • the thickness of the stampable sheet of the present invention is usually 1 to 10 mm, preferably 2 to 5 mm.
  • the thickness of the stampable sheet is 1 mm or more, it is easy to produce the stampable sheet.
  • the thickness of the stampable sheet is 10 mm or less, in the case where the stampable sheet is processed by stamping molding or the like, it is unnecessary to preheat for a long time, and good moldability can be obtained.
  • the resin constituting the fiber-reinforced resin of the present invention is not particularly limited, it can be a thermosetting resin.
  • the thermosetting resin is not particularly limited, and examples thereof include a vinyl urethane resin, an unsaturated polyester resin, an acrylic resin, an epoxy resin, a phenol resin, a melamine resin, and a furan resin.
  • these thermosetting resins may be used alone or in combination of two or more kinds thereof.
  • a vinyl urethane resin, an epoxy resin, and a phenol resin are preferred from the viewpoints of physical properties, versatility, cost, etc. of the resin.
  • thermosetting resin and the fiber can be composited and used as a fiber-reinforced composite material.
  • a prepreg in which a reinforcing fiber base material containing continuous fibers is impregnated with a thermosetting resin composition
  • a sheet molding compound (SMC) in which a reinforcing fiber base material containing short fibers is impregnated with a thermosetting resin composition is used.
  • Compression molding of fiber-reinforced composite materials is widely used as a method of producing fiber-reinforced composite material molded articles.
  • the content of the thermosetting resin in the battery housing of the present invention is preferably 20 to 80% by mass.
  • the content of the thermosetting resin is 20% by mass or more, the molding workability is sufficient, and the molding of the battery housing becomes easy.
  • the content of the thermosetting resin is 80% by mass or less, the content of the inorganic fiber becomes sufficient, and sufficient flame shielding performance can be obtained.
  • the content of the thermosetting resin in the battery housing is preferably 35 to 70% by mass, and more preferably 40 to 60% by mass.
  • press molding is preferable from the viewpoint of productivity.
  • a prepreg in which a reinforcing fiber base material containing continuous fibers is impregnated with a thermosetting resin composition, or a sheet molding compound (SMC) in which a reinforcing fiber base material containing short fibers is impregnated with a thermosetting resin composition is used.
  • SMC sheet molding compound
  • the structure of the present invention has a battery housing and a battery cell.
  • the battery housing of the present invention is as described in detail above.
  • a battery is preferable as the structure in the present invention, and the battery is not particularly limited.
  • a secondary battery such as a lithium ion battery, a nickel-hydrogen battery, a lithium-sulfur battery, a nickel-cadmium battery, a nickel-iron battery, a nickel-zinc battery, a sodium-sulfur battery, a lead-acid battery, and an air battery.
  • a lithium ion battery is preferred, and in particular, the battery housing of the present invention is suitably used for suppressing thermal runaway of the lithium ion battery. That is, the battery housing of the present invention is preferably a battery housing for a lithium ion battery.
  • a mat layer of the inorganic fiber B is arranged on the battery cell side in the battery housing.
  • Electric mobility in the present invention refers to transportation equipment such as vehicles, ships, and airplanes that operate using electricity as an energy source.
  • Vehicles include not only electric vehicles (EV) but also hybrid vehicles.
  • a structure such as a battery having a battery housing according to the present invention and a battery cell as described above is highly safe and is very useful for electric mobility using a battery module with high energy density in order to be capable of extending driving distance. It is particularly useful for electric vehicles.
  • the stampable sheets prepared in each Example and Comparative Example are fixed in a state where 150 mm ⁇ 150 mm of the stampable sheet is exposed such that a flame can be applied to the same place.
  • a flame was applied with a distance between the sample and the burner adjusted to 145 mm under conditions of 0.15 MPa of oxygen and 0.001 MPa of acetylene such that the sample surface temperature became 1200° C.
  • the flame was applied for 5 minutes, and the flame shielding performance was evaluated by visually confirming whether or not the flame penetrated. Evaluation criteria are as follows.
  • a phosphorus-based flame retardant composition (manufactured by ADEKA Corporation, ADEKA STAB FP-2200, containing, with respect to the total mass of the phosphorus-based flame retardant composition, 50 to 60% by mass of piperazine pyrophosphate, 35 to 45% by mass of melamine pyrophosphate, and 3 to 6% by mass of zinc oxide)
  • ⁇ -olefin/maleic anhydride copolymer manufactured by Mitsubishi Chemical Corporation, DIACARNA 30M, weight average molecular weight 7,800.
  • a mat (weight per unit area: 900 g/m 2 ) made from commercially available crystalline alumina fiber (“MAFTEC” (registered trademark) manufactured by Mitsubishi Chemical Corporation) was used.
  • the polypropylene-based resin, a flame retardant, and a dispersant were melt-kneaded (230° C.) in the proportions shown in Table 1 to prepare pellets of a polypropylene-based resin composition (hereinafter referred to as “PP composition 1 ”).
  • the pellets of the PP composition 1 granulated in Preparation Example 1 were placed in an extruder, melted, and then extruded and molded into a sheet shape.
  • the extruded sheet-shaped PP 21 , 21 ′ and 21 ′′ in FIG. 2
  • a glass fiber mat 23 and an alumina fiber mat 22 were laminated by supplying the PP as an outermost layer and supplying the glass fiber 23 and the alumina fiber mat 22 therebetween such that they were respectively in mass ratios of a and b in Table 1.
  • a stampable sheet (thickness: 3.8 mm) was obtained.
  • stampable sheets a and one stampable sheet b obtained above were used and stacked such that b was sandwich by a's from both sides, and the materials were preheated in a far-infrared heating furnace (set temperature: 270 to 300° C.) for 4 minutes to a temperature of 210° C.
  • the stampable sheets were held for 30 seconds while applying a pressure of 150 kg/cm 2 in a press machine equipped with a mold, followed by cooling and solidification to obtain a box-shaped molded article (thickness: 3.0 mm).
  • the results of evaluation by the above method are shown in Table 2.
  • the stampable sheets a to f were prepared such that, in addition to the components shown in Tables 1 and 2, optional additive components were added so that the total was 100% by mass.
  • a molded article (thickness: 3.0 mm) was obtained in the same manner as in Example 1, except that in the method for producing a stampable sheet of Example 1, the contents of the polypropylene resin, the flame retardant, and the dispersant in the resin composition were changed as c and d shown in Table 1, and the housing cover was molded with the stampable sheets stacked such that d was sandwiched by c's from both sides, and the mass ratio was changed to that shown in Table 2. The results of evaluation by the above method are shown in Table 2.
  • a molded article (thickness: 3.0 mm) was obtained in the same manner as in Example 1, except that in the method for producing a stampable sheet of Example 1, the resin composition did not contain a flame retardant and a dispersant, the contents of the glass fiber and the alumina fiber were changed as c and e shown in Table 1, and the housing cover was molded with the stampable sheets stacked such that e was sandwiched by c's from both sides, and the mass ratio was changed to that shown in Table 2.
  • Table 1 The results of evaluation by the above method are shown in Table 1.
  • a stampable sheet was obtained in the same manner as in Example 1, except that in Example 1, pellets and chopped carbon fibers were kneaded in a kneader in the proportions of f in Table 1, and the resulting compound was used to form a sheet without using an alumina fiber mat. Thereafter, a molded article (thickness: 3.0 mm) was obtained in the same manner as in Example 1 except that the housing cover was molded with three f's stacked, and the mass ratio was changed to that shown in Table 2. The results of evaluation by the above method are shown in Table 2.
  • the battery housing of the present invention containing highly heat-resistant fibers has excellent flame shielding performance.
  • the battery housing of the present invention is lightweight because the main component is resin.
  • the battery housing of the present invention has excellent flame shielding performance, and since resin is the main component, it has excellent workability. Moreover, since it is lightweight, a structure using the battery housing of the present invention is useful as an electric mobility.

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US7294431B2 (en) * 2004-04-14 2007-11-13 Ovonic Battery Company, Inc. Battery employing thermally conductive polymer case
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